Analysis of Roller Hemming Process for a Vehicle Tailgate Closure

Date

2013-07-10

Author

Gurgen, Selim
Gökler, Mustafa İlhan
Darendeliler, Haluk
Celikkaya, Cetin Cengiz
Erden, Kemal

Metadata

Show full item record

This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Item Usage Stats

195
views

0
downloads

Hemming is a sheet metal joining process which is widely used for vehicle closures. As the latest hemming process type, the roller hemming process uses industrial robots therefore; main advantage of the process is achieved as flexibility with improved product quality. Trial and error method is the general approach to design the process in the industry due to limited know-how in the roller hemming. However, due to advantages of the process, the recent studies have also been focused on numerical simulations. In this study, the roller hemming process of the tailgate of a vehicle has been investigated by using the finite element method. The points of interest are selected as cycle time reduction and reducing the undesired wrinkling formation in the process. In the current roller hemming process of the tailgate, three stages including two pre-hemming and one final hemming stages are being applied. For the cycle time reduction, simulations have been performed to complete the hemming process in two stages. Effects of the roller geometry and the bending angle pairs have been investigated. The hemming process with two stages has been shown numerically to be applicable by considering the final geometry of the product and the maximum stress and strain values occurred during the process. The wrinkling formation is reduced by using a roller with larger diameter in the simulations. Then, verifications of the simulations have been done by implementing of the process. As a result of the study, approximately 33% reduction in the cycle time and 50% increase in the productivity of the tailgate have been successfully achieved in addition to reduction in the wrinkling formation during the pre-hemming stage.

Subject Keywords

Roller hemming, Finite element methods

URI

https://hdl.handle.net/11511/42527

DOI

https://doi.org/10.1063/1.4806848

Collections

Department of Mechanical Engineering, Conference / Seminar

Suggestions

OpenMETU
Core

Analysis of Reinforced Soil Slopes with Limit Equilibrium and Finite Element Methods Özçelik, Gökçe; Paşaoğlu, Özgür; Huvaj Sarıhan, Nejan (null; 2014-09-21) Reinforcing elements such as geotextiles or geogrids are widely used in retaining walls, slopes and embankments since they provide an economical and practical solution. A reinforced wall transitions into a slope as the slope angle with the horizontal decreases. Therefore, the design methodology transitions from lateral earth pressure theory to slope stability analyses. For slope stability problems both limit equilibrium and finite element methods are being used widely. In limit equilibrium solutions, the re...
MODELING OF DYNAMIC DELAMINATION IN L-SHAPED COMPOSITE BRACKETS Gozluklu, Burak; Çöker, Demirkan (2012-11-15) One of the widely used geometrically complex parts in recent civil passenger aircrafts is the L-shaped composite brackets connecting ribs to skins. Due to the sharp curved geometry, interlaminar opening stresses are induced and delamination occurs under considerable mode-mixities at the corner. Dynamic phenomena during delamination initiation and propagation of L-shaped beams are investigated using dynamic (explicit) finite element analysis in conjunction with cohesive zone methods (CZM). In ABAQUS a sequen...
Development of bolted flange design tool based on finite element analysis and artificial neural network Yıldırım, Alper; Kayran, Altan; Department of Aerospace Engineering (2015) In bolted flange connections, commonly utilized in aircraft engine designs, structural integrity and minimization of the weight are achieved by the optimum combination of the design parameters utilizing the outcome of many structural analyses. Bolt size, number of bolts, bolt locations, casing thickness, flange thickness, bolt preload, and axial external force are some of the critical design parameters in bolted flange connections. Theoretical analysis and finite element analysis (FEA) are two main approach...
Finite element analysis of shearing processes Isbir, S.; Darendeliler, Haluk; Gökler, Mustafa İlhan (null; 2006-12-01) Shearing of sheet metal is extensively used in manufacturing industry. It is a highly non-linear process and involves complex mechanisms such as crack initiation and propagation, and deliberate fracture of the material for obtaining the desired geometry. Finite element method can be used for the design of shearing process. However, most of the general purpose commercial finite element analysis programs do not provide ready-to-use facilities to simulate shearing. In this paper, finite element simulation of s...
Investigating the effect of deformation and annealing texture on magnetic anisotropy in low-C steel sheets by magnetic Barkhausen noise method Akçaoğlu, Fehmi Ümit; Gür, Cemil Hakan; Department of Metallurgical and Materials Engineering (2013) Deformation and annealing texture in the cold rolled low carbon steels is important for sheet metal forming operations and service performance. The aim of this study is to non-destructively investigate the effect of texture on magnetic anisotropy. Various samples having different textures and residual stress states, due to different % reduction in thickness, annealing and stress relieving treatment, were prepared. Texture maps were obtained by Magnetic Barkhausen noise measurements performed with 100 steps ...

Citation Formats

S. Gurgen, M. İ. Gökler, H. Darendeliler, C. C. Celikkaya, and K. Erden, “Analysis of Roller Hemming Process for a Vehicle Tailgate Closure,” 2013, vol. 1532, Accessed: 00, 2020. [Online]. Available: https://hdl.handle.net/11511/42527.